Aqua-Lab MD User Manual - Hydra
Contents
1. Mount to the wall with 4 appropriate anchors FEED WATER CONNECTION PRIOR TO CONNECTION ENSURE THAT THE FEED LINES ARE FREE OF DEBRIS BY FLUSHING OUT THE LINES FOR 15 MINUTES e Connect pre run main water supply line to pump inlet with hose supplied e Single operating pump 1 MNPT e Dual operating pump 1 1 2 MNPT PNEUMATIC CONNECTIONS e Connect pre run 3 8 OD poly feed line to push connect fitting on the side of the primary regulator e Connect 3 8 OD poly lines from arch to each port that will be foaming f there are unused air ports back out the individual line regulator until air no longer flows Hydra Flex Inc 2015 Page 6 1 ELECTRICAL CONNECTIONS HFI MOTOR STARTER a Wire yellow homerun control cables to car wash control panel See diagram below for wiring schematic e Manifold position below designates which port is associated to what color wire e Example if you want Presoak 1 to be on manifold port 2 connect the green wire to your controller relay for Presoak 1 i ERREA HIE supplied motor startar ST TR a eae Make sure all BLUE wires are separately capped with wire nuts so that they do not touch any other electrical conductive objects One Wire Per Nut Ground Green yellow Left to right on water manifold top to bottom on air valves refer to diagram on page 2 Do Not Use Blue Cap With Wire Nut gJ E Control Voltage Constant Hot Brown Neutral Common Red ogo2. 500 PSI Max 34 bar Inlet 333 PSI 23 bar Max Outlet Temperature Range FE 5 Ce Maximum Wrench Torgue 30 ft lbs 41 N m O Hydra Flex Inc 2015 Page 19 PRESSURE LOSS IN RUN LENGTH GREEN GOOD YELLOW USE CAUTION All solution line tubing should be selected for 10 PSI or less of pressure loss 20 PSI pressure loss may be acceptable depending upon nozzle sizing foamers check valves and other line restrictions present in application All numbers represent pressure loss in PSI for selected solution line tubing 5 8 ID BRAIDED Flow Rate GPM at 200 PSI Injector Color gt Nozzle Size 125 100 75 i 50 25 1 2 ID BRAIDED 0 25 0 50 0 75 White Yellow Tan 0 029 0 040 0 051 0 057 0 7 mm 1 0 mm 1 4 mm Flow Rate GPM at 200 PSI l Injector Color Nozzle Size gt Run Length 0 25 0 50 0 75 White Yellow Tan 0 029 0 040 0 051 1 0 mm 0 057 1 4 mm 3 8 ID 1 2 OD POLY TUBE Flow Rate GPM at 200 PSI Injector Color gt 1 00 Nozzle Size gt 125 o 100 5 75 LA 2 50 25 O Hydra Flex Inc 2015 0 25 0 50 0 75 White Yellow Tan 0 029 0 040 0 051 0 7 mm 1 0 mm 0 057 1 4
3. D 0 a o 93 4 gt o 7 i NO Z Z O O jeuBbis oAjeA 1SVHd JOVLIOA TOULNOD Page 9 START UP 1 DISCONNECT amp FLUSH Close ball valve and remove the pump outlet line at the Hydra Cannon Manifold quick connect Image 1 Make sure water supply to pump is turned on Open ball valve and direct toward a drain or container to remove the majority of the air from the pump until a steady stream of water is flowing approx 1 min Then close the ball valve 2 CHECK ROTATION Open Aqua Lab Motor Starter Box MSB and ensure 3 phase disconnect is on Note Door will not open with disconnect on Use a 1 4 wrench or crescent wrench to turn it back on after opening door MSB with blue and black Eaton disconnect can be opened without shutting off by depressing button under switch handle Press small button with screw driver to bypass disconnect Image 2 IWARNING ELECTRIC SHOCK HAZARD HIGH VOLTAGE PRESENT INSIDE MOTOR STARTER BOX USE CAUTION Start the pump momentarily by depressing the center of the contractor image 3 IWARNING RUNNING THE PUMP BACKWARD WILL CAUSE CATASTROPHIC SYSTEM FAILURE ENSURE THAT PUMP ROTATION IS CORRECT image 4 as indicated by the arrow on the casting of the pump and that 200 psi can be reached e If pump cannot regulate to 200 psi remove pump motor cover and look at shaft to confirm correct rotation e Verify pump inlet pressure remains positive when
4. Flexible 4x 3 8 Concrete 1x Connection With Hose With Regulator amp Wye Anchors Included Valve To Accommodate Strainer To AQUA LAB With With Each Pump 1 Male Not Hose Must 1 2 Quick Connect amp Ball Stand Terminate Within 5 Valve Included With Each Feet Of Pump Inlet O1 0 Recommended Pump Stand Provided By Others Located Within 5 Of Each MD Board 1x 12ft 230V 480V Pump Power Cord Included With Each Pump Hydra Flex Inc 2015 Page 4 ESTIMATED INSTALLATION TIMELINE PRE INSTALLATION WHO TASK EST TIME DISTRIBUTOR amp CUSTOMER DETERMINE LOCATION TO INSTALL EOUIPMENT PLUMBER INSTALL WATER SUPPLY LINE TOTAL LABOR HOURS 16 HRS INSTALLATION WHO TASK EST TIME TOTAL LABOR HOURS 8 HRS POST INSTALLATION WHO TASK EST TIME DISTRIBUTOR MONITOR amp RECORD PERFORMANCE 2 HR WK DISTRIBUTOR MAINTENANCE PER SCHEDULE OR AS NEEDED TOTAL HOURS SPENT TOTAL CUSTOMER TOTAL DISTRIBUTOR TECHNICIAN 15 HR Installation takes approximately ONE day An electrician and a plumber are needed for half a day TOTAL ELECTRICIAN AHR TOTAL PLUMBER AHR INSTALLATION INSTRUCTIONS General Skill Level e Mechanical Basic mounting equipment e Electrical Advanced three phase power and controls knowledge local codes knowledge required e Plumbing Moderate principal supply line required e Pneumatic Basic pneumatic utility connection required e Chemical Knowledge Moderate chemical titrations r
5. Hydra Cannon Port 1 White Hydra Cannon Port 2 Green Hydra Cannon Port 3 Yellow Hydra Cannon Port 4 Grey Hydra Cannon Port 5 Pink WM ee b Remove the cap from port 6 then connect the grey M12 cables hanging out of the motor starter box to the NEUTRAL COMMON port 6 of the yellow M12 junction boxes i If you have more panels than gray wires from the motor starter box connect the lose gray wires sent in the shipment into the same jumpers as the pre wired gray cables This step must be completed for unit to function c Connect Powerfast Cordset on motor s to motor starter box d In the lower left of the enclosure wire each leg of the incoming power to the terminals labeled 711 472 and olo e Make sure to follow all applicable electrical codes 2 ELECTRICAL CONNECTIONS ONLY FOR SYSTEMS RUNNING WITH NON HFI MOTOR STARTER a Connect yellow homerun control cables to car wash control panel See diagram to the right for wiring schematic e Manifold position below designates which port is associated to what color wire e Example if you want Presoak 1 to be on manifold port 2 connect the green wire to your controller relay for Presoak 1 Left to right on water manifold top to bottom on air valves refer to diagram on page 2 b Wire each leg of Ground Green yellow power from your Neutral Common Blue Stance o ac Do Not Use Brown Cap With Wire Nut pum Do Not Use Red Cap With Wire Nut i See
6. diagram on pump for wiring schematic Hydra Cannon Port 2 Green or pump manual Hydra Cannon Port 3 Yellow Hydra Cannon Port 1 White Hydra Cannon Port 4 Grey Hydra Cannon Port 5 Pink O Hydra Flex Inc 2015 Page 7 WIRING DIAGRAM SINGLE PUMP Thermal Overload Current Switch Disconect Gmm89 3 Phase mn HR 29 000000 O O EE From Grey M12 Cables From Breaker Port 6 on M12 Block 2T1 AT2 ro s _ Control Voltage Gy 3 Phase wlelel gt gt xjx c S S a a a a z l a s sis s a mimimimimlio oojpojpopop o Jumper Jumper To Pump Through Power Fast Ouick Connect O Hydra Flex Inc 2015 Page 8 MULTI SOURCE DUAL PUMP Jayeeig WO4 120uo gt si O ETE 12euuo7 AAND 3se4 Jamog yBnoiy dung OL g un Q D Q e OI KO BRU RS cu se ge ZLIN wWoJ4 Hydra Flex Inc 2015 Oe rey m O cen O OMC O en CO e 9 O ceu 9 OMC O cwx 9 Q O cwm 9 O O ce MONO EG ___ 2 o tnn o _r yw ce 71 rez o ri MEAN EMP2 e n Can y je Em uc He B Gau po lt HM Le 3 Rene A1 ICE L fesse cul ECH CSN So lleon CO PO ie LC lleon CO ROMEO Valve Signal 2 peoj4o 0 euuoug peoj49 0 gt O 4 Q z 9 D 0 eno w 93 a m E ai i NO Z Z O O gt O 4 Q yd o
7. AOUA LAB MD CHEMICAL DISPENSING SYSTEM User Manual REV P 2 i EPHYDRAELEX hydraflexinc com AQUA LAB MDS5 Chemical Dispensing System i 6 4000022 revP1015 O Hydra Flex Inc 2015 HYDRA FLEX FLUID INNOVATION d TABLE OF CONTENTS Specifications AOUA LAB MD System Diagrams Motor Starter Pump Diagram Layout Drawing Estimated Installation Timeline Installation Instructions Wiring Diagram Single Pump Multi Source Dual Pump SO CoO O O A O N O Startup Initial Injector Setup 11 11 12 12 Triple Foam Setup Optimizing The System Nozzle Setup Chemical Usage Measurement __ 13 Recommended Maintenance d GG 14 Air Operated Valve Replacement 14 Trouble Shooting 14 Pump Issues 14 Injector Issues 15 Pressure Regulator Issues 15 Flow Arch issues 16 Valve Issues 16 Injector Optimization Troubleshooting 16 Injector Vacuum Check 17 Appendix 18 Chem Flex Injector Dilution Ratio Chart 18 Recommended Setup Starting Point 19 Chem Flex Injector Part Numbers 19 Pressure Loss In Run Length 20 Aqua Lab Warranty 21 SPECIFICATIONS POWER REOUIREMENTS PUMPS AIR ACTUATED VALVES 20 GPM 24 VAC or 24 VDC or 120 VAC 3 5 Watts Per Port 208 230V 3PH 8 9A or 460V 3PH 4 1A or 575V 3PH 4 1A DIMENSIONS W x H PUMP ASSEMBL
8. AY 158 1 6 7 1 6 9 1 7 6 1 10 1 16 OPEN 1 4 9 1 5 3 155 2 1 6 0 176 1 1 10 There may be slight variations of performance in injectors and metering tips that are unavoidable due to manufacture tolerances Using the same tip color from site to site is a good starting point However with the potential for variation from part to part it is reasonable to still need to do some adjustments from there SPIRAL METERING PLUGS Flow Rate GPM at 200 PSI Injector Color gt Nozzle 0 029 0 040 0 051 0 057 0 070 0 083 0 086 0 098 0 125 Size 0 7 mm 1 0 mm 1 3 mm 1 4 mm 1 8 mm 2 1 mm 2 2 mm 2 5 mm 3 2 mm 3 00 1 251 1 503 1 754 1 1006 1 1509 1 2012 1 2263 1 3269 1 5532 E 2 00 1 181 1 363 1 544 1 726 1 1089 1 1451 1 1633 1 2359 153041 4 1 00 1 104 1 208 15 311 1415 1 623 1 831 1 934 1 1350 1 2284 D 0 75 1 82 1 165 1 247 1 329 1 494 1 659 1 741 1 1071 1 1812 T 0 50 1 57 1112 1 178 1 238 17357 1 475 1 535 177 1 1307 N 0 25 1 34 1 68 1 102 1 136 1 204 12272 1 306 1 442 1 748 Remove all standard metering tips when using a Metering Plug in an application 3 8 Polyflow LLDPE tubing is required to ensure a seal between the tube wall and the flats on the OD of the Meter Plug Hydra Flex Inc 2015 Page 18 RECOMMENDED SETUP STARTING P
9. IES PANELS MOTOR CONTROL UNIT Single Dual 24 x 48 24 x 48 36 x 48 22 x29 22 x 29 14 x 15 WATER SUPPLY Water Inlet Lines 20 GPM 40 GPM 1 ID 1 1 2 ID or 2x 1 ID Up to 3 GPM 2355 GPM 6 8 GPM Solution Outlet Lines AIR SUPPLY Air Inlet Line 3 8 OD Polyflow Per MD Panel Air Outlet Line 3 8 OD Polyflow Per Application Air Inlet Pressure 60 120 PSI Dry Air FOR ADDITIONAL SUPPORT CALL 952 808 3640 OR VISIT US ON THE WEB www hydraflexinc com O Hydra Flex Inc 2015 Page 1 AOUA LAB MD SYSTEM DIAGRAMS AQUA LAB MD3 ec ZPHYDRAFLEX hydrafiexine com Mounting Slots 2 top 2 Bottom AQUA LAB MD5 3A 3B 3C Chemical Dispensing System A Air Ports Back _ Patent Pending Primary Air Regulator Solenoid Actuated Air Valves Individual Air Regulators Goes To Motor Starter Box Hydra Cannon WM Manifold Manifold Air Ports Back Solution Ports Front M12 Junction Block Home Run Cable Goes to car wash controller for control voltage Grey M12 Cable FOR PART NUMBERS amp DIAGRAMS Visit www hydraflexinc com and click on our Literature Tab located in the top right corner of our website Then scroll down to the Sales Literature section amp select the Vehicle Wash Catalog O Hydra Flex Inc 2015 Page 2 MOTOR STARTER PUMP DIAGRAM SINGLE SOURCE SINGLE PUMP SHOWN SPRECHER amp SCHUH EATON 2
10. OINTS APPLICATOR Scent Dispenser INJECTORS PART NUMBER COLOR CTA Nozzles For Showerhead See Below Foam Stick Mitter Warp Nozzles 618083 2 0 GPM 618086 2 25 GPM Undercarriage Rust Inhibitor V Jet Or Flat Fan Nozzle Arch K12 Nozzle Arch 618086 2 25 GPM K15 Nozzle Arch Hockey Puck 3 Rows Of Holes Showerhead 1 Row Of Holes 618086 2 25 GPM Rain Bar Quad Foam w 4X 618086 2 25 GPM Triple Foam w 3X 618086 2 25 GPM Foam Curtain Choose Foam Accessory Based On Of Inputs Foam Generators High Flow Foam Curtain Application 10 GPM High Flow Device w 618086 2 25 GPM Foaming Air Start at 25 PSI adjust based on unique application CHEM FLEX INJECTOR PART NUMBERS QUICK CONNECT INJECTORS PC2 X 3 8 NPT CONNECTIONS For exclusive use with Aqua Lab Chemical Dispensing Systems COLOR FLOW FLOW RATE SINGLE BARB DUAL BARB TRIPLE BARB ORIFICE 200 PSI WHITE 0 029 25 GPM sm 618029 YELLOW 0 040 5 GPM do 618040 wb 629040 TAN 0 051 75 GPM yy 618051 wey 629051 ay 639051 RED 0 057 1 0 GPM 618057 be 629057 639057 ORANGE 0 070 1 5 GPM 618070 629070 639070 GRAY 0 083 2 0 GPM do 618083 3 629083 i 639083 BLUE 0 086 2 25 GPM 618086 Be 629086 Wi 639086 LIGHT GREEN 0 098 3 25 GPM do 618098 hy 629008 639098 DARK GREEN 0 125 5 5 GPM 618125 o 629125 63125 SPECIFICATIONS Pressure Range Up to
11. Timer Relay 4 4 Current i Switch Contactor i 3 Phase Disconnect Thermal 4 hi Overload Contactor Current l Timer Relay Switch i Bn Thermal f 3 Phase 1 rr Overload 4 Disconnect 2 Quick A FF Ouick LES A Connect a ug TT Pump Plug FD Female Grey M12 Cables Carry signal from Grey M12 Cables Carry signal from yellow M12 distribution block to yellow M12 distribution block to motor starter that turns on the pump motor starter that turns on the pump Ouick Connect 9 Cordset For Pump Plugs Into Bottom Of Motor Starter Thermal Relief Valve Back up Pump Bypass Pressure Regulator Pump Outlet Feed Line To MD Panels FOR PART NUMBERS amp DIAGRAMS Visit www hydraflexinc com and click on our Literature Tab located in the top right corner of our website Then scroll down to the Sales Literature section amp select the Vehicle Wash Catalog Wye Strainer O Hydra Flex Inc 2015 Page 3 LAYOUT DRAWING Motor ae 2x 20 Signal Wire Located Within 10 Of To AQUA LAB Included Aqua Lab 3 Phase 480v Or 230V Power Is Provided By Others 1x 230V 480V Pump Power Receptacle Included 4x Tapcon Anchors Included For Each MD 5 Port 2x 3 8 Poly Flow AOUA LAB MD Air Inlet Tubing Provided By Others 100 PSI Max 30 Signal Control Cable Included 1x 6 X O1 0 MNPT Ouick Change Pump Inlet Hose AppROX 259 Included 48 54 IN ll J 1x 6 Ouick Change
12. age 12 INJECTOR FLOW RATE 6 200 PSI GPM INJECTOR FLOW RATE 6 200 PSI GPM MINIMUM NUMBER OF NOZZLES NECESSARY WITHOUT FOAMING AIR Assuming lt 10 PSI line loss and 40 PSI at the nozzle SPRAY NOZZLE SIZE 2 0 3 0 4 0 5 0 6 0 7 0 8 0 9 0 10 0 1 1 1 1 1 1 1 1 1 2 1 1 1 1 1 1 1 1 3 2 1 1 1 1 1 1 1 5 3 2 2 1 1 1 1 1 7 5 3 3 2 2 1 1 1 10 6 5 4 3 2 2 2 2 11 7 5 4 3 3 2 2 2 16 10 8 6 5 4 4 3 3 27 18 13 11 9 7 6 6 5 MINIMUM NUMBER OF NOZZLES NECESSARY WITH FOAMING AIR Assuming lt 10 PSI line loss and 40 PSI at the nozzle SPRAY NOZZLE SIZE 2 0 3 0 4 0 5 0 6 0 7 0 3 0 9 0 10 0 4 1 1 1 1 1 1 8 3 2 2 2 1 1 13 8 5 4 3 3 2 2 17 11 7 5 5 4 3 3 26 17 13 10 8 7 6 5 5 35 23 17 14 11 10 8 7 7 39 26 19 15 13 11 9 8 7 56 37 28 22 18 16 14 12 11 96 64 48 38 32 27 24 21 19 Elbows Pipe Fittings e Elbows and other pipe fittings add back pressure by causing the fluid to change direction and l 2 3 thus changing the fluid s momentum Try to find simpler ways to route your fluid without elbows Line Length e Longer lines add back pressure due to the inherent resistance caused by friction See if you can reduce the line length or increase the inside diameter CHEMICAL USAGE MEASURING VERIFY TITRATION OF CHEMICALS BEFORE PROCEEDING Set up la
13. ant hot not connected g Pp wash controller Could be due to blown pump motor Try to turn breaker back on or replace fuse If breaker trips after trying to fire motor it is most likely burned out Replace with new motor and pump Defective motor starter contactor Replace motor starter contactor Pump Will Not Start Or Run At Thermal overload set too low tripped Adjust setting on thermal overload to match voltage Full T le Voltage must be within 10 of motor rated voltage Incorrect motor voltage Check that pump is wired for correct voltage Defective motor Replace motor 3 phase disconnect ued of Pump components damaged Replace worn part or entire pump Current Sensor not seeing any Turn on one valve and verity red light blinks fast verify current at least 10 wraps of wire around current sensor Pump not secured firmly Secure properly Restricted inlet Clean or correct restriction Try to adjust regulator down and then back up or replace regulator remove check valves pressure regulators from H20 feed to pump Cavitation sounds like marbles in pump Increase inlet size inlet pressure Worn mechanical seal Replace pump Not primed Re prime pump Loose fittings and or not enough Tighten fittings and or take part off and put new Pump Leaks thread tape thread tape on INJECTOR ISSUES PROBLEM POTENTIAL CAUSES SOLUTIONS Injector Is Not Drawing Chemical Check chemical hose foot valve metering tip and Passes Vacuum Pr
14. b scale with small bucket of chemical to be measured gt Put the suction line into the bucket Run the application being tested to prime the line All air bubbles must be removed for accuracy y AT S a a aZ p 2 T e gt Record the Initial Weight from the scale Tarring the scale with weight on the scale can affect accuracy Run the application for 1 vehicle or manually for the same amount of time it would be on for 1 vehicle Record the Final Weight from the scale Subtract the Initial Weight from the Final Weight to determine the weight of used product Divide the Per Car Weight in grams by the specific gravity of the chemical to determine the milliliters of chemical used per vehicle Repeat for each chemical application Hydra Flex Inc 2015 Page 13 RECOMMENDED MAINTENANCE THE RECOMMENDED SERVICE AND MAINTENANCE ON THE AOUA LAB SYSTEM ARE AS FOLLOWS Monthly e Check drain primary air regulator filter separator e Check water filter and replace as needed if installed e Check and clean wye strainer Semi Annually e Check and replace injector metering tips e Inspect and replace chemical lines as needed e Ensure lines are tightly secured to injector hose barbs clip 1 off old hose as needed that was stretched by hose barb Annually e Clean water regulator e Inspect motor starter for corrosion if identified order replacement spare parts 1 3 Yea
15. dry e Decrease foaming air pressure e Increase injector size increases water e Decrease metering tip decreases chemical e Nozzle sputters e Decrease foaming air pressure e Decrease number of nozzle s and or size used on arch e Increase injector size increases water e Too much chemical used e Decrease metering tip e Decrease metering tip and injector size to maintain desired ratio Metering Tip 1 4 Poly Tube Chemical 200 PSI Water 66 PSI Max Solution e No chemical e Check vacuum backpressure of injector for clogging see page 17 for Injector Vacuum Check Instructions or pages 15 for troubleshooting e Check foot valve e Check metering tip e Nozzle fan pattern not filled e Reduce nozzle size e Increase injector size increases water e Water not present at all nozzles on arch Verify check valves are functioning Verify nozzles are not plugged Reduce number of nozzles Reduce nozzle size Increase injector size increases water NOZZLE SETUP Optional For Maximized Optimization e Using the recommended starting point appendix install the recommended nozzles e This may involve removing and plugging some ports e Due to the lower water usage determined by the injector of the AQUA LAB you will need to match the flow of the application device to the injector e Setup the nozzle spray patterns to paint the car slightly overlapping each other Hydra Flex Inc 2015 P
16. e are based on drawing water through the metering tips and are meant as a starting point for system configuration Results are expected to vary when drawing chemicals due to differences in viscosity and temperature 8 32 METERING TIPS Flow Rate GPM at 200 PSI Injector Color gt Nozzle Size gt COPPER amp 1 57 1 104 1 155 1 195 1 281 1 406 1 468 1 629 1 1074 PUMPKIN amp 1 43 1 82 1 119 1 126 1 238 1 348 1 398 1 554 1 946 BURGUNDY amp 1 34 1 67 1 97 1 111 1 207 1 304 1 347 1 495 1 845 LIME e 1 28 1 57 1 81 1 100 1 183 1 270 1 307 1 447 1 764 TAN 1 28 1 57 1 81 1 100 1 183 1 270 1 307 1 447 1 764 ORANGE amp 1 23 1 44 1 64 1 78 1 137 1 196 1 215 1 314 1 536 TURQUOISE 1 17 1 31 1 45 1 55 1 91 1 126 1 134 1 197 1 336 PINK amp 1 14 1 24 1 35 1 42 1 68 1 93 1 98 1 143 1 224 LIGHT BLUE amp 1 11 1 17 1 24 1 31 1 47 1 64 1 66 1 98 1 166 E BROWN amp 1 10 1 15 1 22 1 28 1 43 1 58 1 59 1 88 1 150 RED amp 1 12 1 17 1 23 1 34 1 45 1 46 1 69 1 116 WHITE 1 12 1 16 1 22 1 31 1 42 1 43 1 64 1 108 GREEN amp 1 11 1 14 1 20 1 28 1 37 1 38 1 55 1 94 BLUE amp 1 10 1 12 1 17 1 23 1 30 1 31 1 46 1 77 YELLOW ED 19 1 12 1 16 1 20 1 22 1 31 1 52 BLACK F 1 10 1 13 1 16 1 17 1 24 1 40 PURPLE amp 1 6 6 1 8 3 1 9 1 10 1 13 1 21 GR
17. equired Tools amp Equipment Needed Useful Tools e Drill with Phillips head Hammer e Utility knife e Adjustable wrench e Amp Meter e Concrete drill bit 3 8 e Tape measure Wire stripper Screw driver set e Volt Meter e Concrete drill bit 5 32 e Level e Socket set e Teflon tape Hydra Flex Inc 2015 Page 5 UNPACKING The AOUA LAB MD is shipped in a crate for protection 1 Cut straps holding crate together lift off top and sides 2 Un bolt the pump from the pallet 3 Lift the pump from the pallet Use assistance if necessary 4 Be sure not to discard the manuals and accessories box LOCATION amp MOUNTING f location was not identified during the Pre Installation Process make sure to consider the proximity to feed water power supply and the control cabinet as well as space near the system to store chemical containers See drawing in reference for general layout AOUA LAB MD 1 Drill 4 5 32 holes on the wall 16 3 8 wide 27 5 8 tall 2 Press MD board tight against the wall 3 Screw in 3 16 concrete screws with a washer PUMP ASSEMBLY NEED TO BE WITHIN 6 OF FURTHEST AQUA LAB PANEL 1 Drill 3 8 holes in wall for bottom slots 20 on center pump nose down 3 5 on center pump nose sideways dual stand 2 Insert concrete anchors set pump on bolts and tighten down 3 Hold pump stand in place drill top holes insert anchors and tighten MOTOR STARTER 1
18. essure Check 99 hose barb for debris or clogs velve pre Hurston valve matoaening Ensure minimum 60 psi on primary air regulator ensure valve receiving signal NO Fow Frominjector Clogged injector Remove injector and blow out debris with compressed air No water supply Check that the system has a supply of water Clean or replace downstream check valves increase Too much back pressure on injector nozzle size or quantity use larger tubing or use smaller flow injectors Clogged injector check valve Blow compressed air through the chemical hose barb Injector Is Not Drawing Chemical on the injector to remove debris Fails Vacuum Pressure Check Clogged injector nozzle Remove injector and blow out any debris with compressed air Defective injector Replace injector Product specific Sonny s Rain Bar Remove elbow at inlet to foam generator and remove nozzle Remove end fittings and retention rod Clean out inlet Manifold inlet clogged rare a de lo Call Hydra Flex and order composite version of injectors PRESSURE REGULATOR ISSUES PROBLEM POTENTIAL CAUSES SOLUTIONS Pump not primed Follow priming instructions Debris in regulator Remove regulator and clean out debris Motor rotation incorrect Verify rotation switch 2 leads System is limited by size of pump and size of injectors Opening too many valves at once increase flow by adding secondary pumps or reduce size number of injectors open Defective check valve if ap
19. he supplied coupler and push connect fitting a Be sure to use Teflon tape when connecting the injector to the coupler and push connect fitting to ensure there are no leaks b Do not over tighten poly fittings or they may crack 3 Connect 4 poly lines from each chemical container to the hose barb on the appropriate injector a Ensure a foot valve or similar check valve filter is installed on each line i These must be present or metering tips may clog 4 Metering tips will need to be installed to set dilution ratio see appendix Page 18 for ratio charts to determine tip TRIPLE FOAM SETUP For AOUA LAB MD if ordered with extra regulators If your MD5 panel was ordered with 3 air valves and 5 air regulators or with 5 air valves and 7 air regulators the below instructions will show you how to setup your triple foam 3 Valve 5 Regulator MD Panel e Your triple foam has been setup from the factory to be in port 3 e Insert your triple foam manifold into position 3 with your selected injectors already inserted e On the side of the panel the 3A 3B and 3C regulators see page 2 for reference will control the air to each of your triple foam colors e Insert your air lines to the arch into the bulkhead fittings on the bottom of the panel The 3A 3B and 3C bulkhead see page 2 for reference will be the airlines for each color 5 Valve 7 Regulator MD Panel e Your triple foam has been setup from the factory to be in p
20. inet An injector that is working properly will have a reading greater than or equal to 20 in Hg If vacuum reads lt 20 in Hg image B remove solution metering tip image C and retest a If retest vacuum reads gt 20 in Hg image D The Injector flow too low Increase injector size Nozzle size too large Reduce nozzle size INJECTOR VACUUM CHECK solution metering tip is clogged Replace the metering tip b If Retest vacuum reads lt 20 in Hg continue to STEP 5 Remove a nozzle on the arch or the chemical feed line from the foam generator and retest vacuum a If retest vacuum reads gt 20 in Hg back pressure is being created Continue to STEP 6 b If back pressure is not still not being created try these steps and retest after each 1 Clean nozzle tips 2 Loosely replace media in foam generator Do not over pack 3 Decrease air pressure for foaming 4 Try smaller injector this will produce less flow and thus less back pressure c If retest vacuum reads lt 20 in Hg replace injector and retest If vacuum continues to read lt 20 in Hg call your service provider Repeat steps 2 5 for each chemical lane that a vacuum reading is needed for Once testing is complete turn off the AQUA LAB pump from the main car wash control cabinet Hydra Flex Inc 2015 Page 17 APPENDIX CHEM FLEX INJECTORS CHEMICAL DILUTION RATIOS Assumes feed pressure of 200 PSI NOTE Dilution ratios given abov
21. ly to any equipment which has been subject to misuse inappropriate use of tools including exposure to harsh chemicals neglect lack of maintenance freezing fluid hammer accident third party damage fluid impurities such as sand or minerals acts of God or acts of war Nor does it apply to any eguipment which has been repaired or altered by anyone not so authorized by Hydra Flex Inc All eguipment must be properly installed in accordance with specified plumbing electrical and mechanical reguirements The warranty does not apply to normal wear and tear or routine maintenance components as described in the equipment manual Except as expressly stated herein Hydra Flex Inc shall not be liable for damages of any kind in connection with the purchase maintenance or use of this equipment including loss of profits and all claims for consequential damages This limited warranty is in lieu of all other warranties expressed or implied Hydra Flex Inc neither assumes nor authorizes any person to assume for it any other obligation or liability in connection herewith This warranty is neither assignable nor transferable Transportation damage claims are to be submitted to the carrier of the damaged material 24 HYDRA FLEX FLU I INNOVATION 680 East Travelers Trail e Burnsville MN 55337 T 952 808 3640 F 952 808 3650 www hydraflexinc com info hydraflexinc com Hydra Flex Inc 2015 4000022 revP1015 Page 21
22. mains Open After Signal Manifold pressure is above 230 psi Reduce pressure to manifold to 200 psi operating pressure Is Off Air exhaust muffler is clogged Replace exhaust muffler INJECTOR OPTIMIZATION TOOL BACKGROUND This tool is for initial setup and troubleshooting of Chem Flex Injectors and an Aqua Lab Chemical Dispensing System In order for the injector to work properly and draw chemical this gauge must be in the GREEN section when installed immediately after an injector that is running If the gauge is in the red you will either see intermittent chemical no chemical draw or chemical being applied at a very low pressure Valve Leaks Air Or Water Out Internal o ring seal damaged Top worn Back pressure refers to the pressure in the solution output line Excessive back pressure is the main reason that injectors will not draw If there is ever any concern to why an injector is not drawing chemical the best and easiest way to diagnose the problem is to check the back pressure See instructions below STEPS 1 Plug the optimization tool into the outlet line of injector and connect solution output line PA Hydra Cannon Valve Injector 2 Turn on function from car wash controller to actuate Hydra Cannon valve such that fluid is flowing through both the injector and injector optimization tool and out to the applicator Injector Optimization Tool eo Chemical Draw Line 3 Read i
23. mm 0 070 0 070 1 8 mm 1 50 0 070 18 PSI 14 PSI 12 PSI 0 083 0 083 2 1 mm 2 00 0 083 0 086 0 086 2 2 mm 11 PSI 2 25 0 086 18 PSI 12 PSI 15 PSI INJECTOR 1 00 1 50 2 00 2 25 3 25 5 50 0 098 0 125 3 2 mm 18 PSI 16 PSI INJECTOR 1 00 1 50 2 00 2 25 3 25 5 50 0 098 2 5 mm 0 125 3 2 mm 18 PSI 14 PSI 11 PSI 18 PSI 3 25 5 50 0 098 0 125 13 PSI Page 20 AOUA LAB MD WARRANTY FACTORY LIMITED Hydra Flex Inc warrants its eguipment to be free from defect in material or workmanship under proper normal use for a period of one 1 year beginning the date of purchase Hydra Flex Inc s liability shall be limited to repair or replacement of parts found to be defective within the warranty period and following Hydra Flex Inc s inspection Hydra Flex Inc shall have the option reguiring the return of defective material to establish the purchaser s claim In the event of repair or replacement this limited warranty is non cumulative Neither labor nor transportation charges are included in this warranty This warranty is based upon the proper care and maintenance of the warranted eguipment Warranty does not apply if the merchandise is altered or modified in any way Warranty does not app
24. njector optimization tool If the gauge is in the RED ZONE the back pressure of the L outlet line is either too low or too za high See steps below to correct WW Solution Output Line Chemical Bucket O Hydra Flex Inc 2015 Page 16 BACK PRESSURE TOO HIGH UPPER RED SECTION Back Pressure May Be Affected By One Or Several Of These Things 1 Foam generators are clogged degraded Clean or replace media in generator 2 Injector flow size is too large Go down an injector size less GPM 3 Nozzle size on the arch is too small Go up in nozzle size 4 Check valves are dirty and or failing Clean or replace check valves 5 There is a kink in the line or excess fittings elbows and reducers increase the back pressure Check line and replace any kinked sections Try to reduce fittings 6 ID of tubing going out to the tunnel is too small Go up a size in inside diameter 7 Check valves have too high of cracking pressure Replace check valve with lower pressure check valve 8 Clean foot valve BACK PRESSURE TOO LOW LOWER RED SECTION Back Pressure May Be Affected By One Or Several Of These Things FOR TROUBLESHOOTING INJECTORS 1 1 2 At the Chem Flex injector remove the chemical feed line from the injector hose barb Attach the tubing of the vacuum gauge to the Chem Flex hose barb Image A With the pump s on manually activate the chemical that is to be tested at the main car wash control cab
25. ort 5 e Insert your triple foam manifold into position 5 with your selected injectors already inserted e On the side of the panel the 5A 5B and 5C regulators see page 2 for reference will control the air to each of your triple foam colors e Insert your air lines to the arch into the bulkhead fittings on the bottom of the panel The 5A 5B and 5C bulkhead fittings see page 2 for reference will be the airlines for each color Note Occasionally if all three regulators are pre set too high you may need to lower all three regulators to their lowest setting and then turn them up to the desired pressure O Hydra Flex Inc 2015 Page 11 OPTIMIZING THE SYSTEM CONSISTENTLY ACHIEVE THE DESIRED CLEANING AND PRESENTATION PERFORMANCE USING THE LEAST AMOUNT OF CHEMICAL AND WATER INJECTORS VS METERING TIPS VS NOZZLES THE KEY TO OPTIMIZING THE SYSTEM IS THROUGH TRIAL AND ERROR DON T BE AFRAID TO TRY THESE STEPS TO ACHIEVE YOUR IDEAL PERFORMANCE What do injectors do e ncreases or decreases the amount of water in the solution What do metering tips do e Increases or decreases the amount of chemical in the solution What do nozzles do e Determines the pattern and back pressure of the solution APPLICATION OPTIMIZATION REPEAT FOR EACH APPLICATION Application too wet e Increase foaming air pressure e Reduce injector size decreases water e Increase metering tip increases chemical Application too
26. plicable Replace check valve Defective Regulator Replace regulator Defective Pump Replace Pump Blown fuse or circuit breaker Water regulator fluttering Excessive Noise From Pump chattering System Won t Regulate Up To 200 Psi O Hydra Flex Inc 2015 Page 15 FLOW ARCH ISSUES PROBLEM POTENTIAL CAUSES SOLUTIONS Incorrect injector flow rate a i Replace with larger injector selection System pressure too low Ensure system pressure is set at 200psi Flow At Arch Is Too Low Foam generator plugged Ensure cleaned and clear Increase size of plumbing tubing ensure check Downstream plumbing restrictive valves are cleaned or new reduce elbows in line or other turns that would restrict VALVE ISSUES PROBLEM POTENTIAL CAUSES SOLUTIONS NN ne ene T Ensure primary air regulator reading at least 60 psi turn up to 80 90psi if possible and check again Valve Will Not Open o Remove valve from manifold Carefully remove top of Internal valve o ring jammed valve caution under high spring pressure push white twisted piston up with small allen wrench from opposite end and check o ring condition Replace and lubricate if needed Remove valve from manifold Carefully remove top of valve caution under high spring pressure push white piston up with small screwdriver from opposite end and check o ring condition Replace with 018 amp 008 Viton O ring and lubricate with Dow 111 valve lube Valve Re
27. rs e Inspect and replace injectors e Replace water valves e Replace main pressure regulator AIR OPERATED VALVE REPLACEMENT Shut off the ball valve to MD or Hydra Cannon manifold Disconnect air line from front of valve Unscrew quick connect fitting by hand DO NOT LOSE BLACK WASHER Unscrew valve assembly from the Hydra Cannon manifold Screw new valve into manifold until hand tight and threaded pilot port is facing forward 6 Remove the cap from pilot port and thread in quick connect fitting to front of valve HAND TIGHT ONLY Al ge pa Unscrew from manifold using this 7 Push air line back into fitting portion of valve 8 Open the ball valve to the Hydra Cannon manifold TROUBLESHOOTING PUMP ISSUES PROBLEM POTENTIAL CAUSES SOLUTIONS Pump Operates But Only Delivering 100 150 Psi Incorrect motor rotation Reverse rotation by interchanging two leads Missing 1 of 3 phases Wire according to diagram check breaker turn off on back aileni ee Check pressure on inlet side of pump to be sure Pude Operates But Delivers 1 PE positive pressure is maintained Little Or No Water Undersized piping Replace with larger piping Leak on the inlet side Make sure connections are tight Worn or defective pump parts Replace worn parts or entire pump clean parts if reguired O Hydra Flex Inc 2015 Page 14 PROBLEM POTENTIAL CAUSES SOLUTIONS Make sure constant control voltage is supplied in car Const
28. running 3 PURGE BYPASS Start the pump and slowly open ball valve until it is wide open Allow to run tor 60 seconds to flush lines and then close valve 4 RECONNECT Reconnect the pump outlet line to the Hydra Cannon Manifold and open ball valve 5 DOUBLE CHECK Confirm that the pump can obtain 200 psi while firing solenoids and that the pump housing stainless steel tube is cool to the touch after a minute IN Operation e lf housing is hot or noisy pump did not prime correctly e lf pump does not prime repeat steps 3 5 e lf not at 200 psi and the pump is correctly rotating you may need to adjust the bypass regulator to obtain 200 psi Image 5 Verify pump prime 24 hours after operation to ensure prime held Pay close attention to the temperature of the pump shaft the whole stainless steel area Image 6 should be the same temperature If it starts getting hotter than the supply water or greater than 140 then it is likely that the pump did not prime correctly which WILL CAUSE DAMAGE TO PUMPS The motor housing painted portion will be hot during operation O Hydra Flex Inc 2015 Page 10 INITIAL INJECTOR SETUP Based on field experience this is HFI s recommended starting point 1 Using the recommended starting point Page 19 or the target flow rate and the chemical dilutions chart appendix Page 18 install the appropriate injector into each port 2 Connect pre run solution lines to each injector with t
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